Ioline FJ Printer User manual

Service Manual
Ioline
FJ Printer™
& StudioJet™

Trademarks
Ioline, StudioJet, FJ Printer, FJ-F, FJ-8, FJ-FeX and FJ-8eX are trademarks of Ioline Corporation. HP is
a trademark of the Hewlett-Packard Company. Other product names, logos, designs, titles, words or
phrases mentioned within this publication may be trademarks, service marks, or trade names of Ioline
Corporation or other entities and may be registered in certain jurisdictions including internationally.
Ioline Disclaimer
IOLINE CORPORATION PROVIDES THIS MANUAL “AS IS” WITHOUT WARRANTY OF ANY KIND,
EITHER EXPRESS OR IMPLIED, INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES
OR CONDITIONS OR MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. IN NO
EVENT SHALL IOLINE, ITS DIRECTORS, OFFICERS, EMPLOYEES OR AGENTS BE LIABLE FOR ANY
INDIRECT, SPECIAL, INCIDENTAL, OR CONSEQUENTIAL DAMAGES (INCLUDING DAMAGES
FOR LOSS OF PROFITS, LOSS OF BUSINESS, LOSS OF USE OR DATA, INTERRUPTION OF BUSINESS
AND THE LIKE), EVEN IF IOLINE HAS BEEN ADVISED OF THE POSSIBILITY OF SUCH DAMAGES
ARISING FROM ANY DEFECT OR ERROR IN THIS MANUAL OR PRODUCT.
Limit of Liability Statement
This manual is provided for informational purposes only. The contents are subject to change without
notice and Ioline Corporation assumes no responsibility for any errors that may be contained herein.
Ioline has made every effort to make the StudioJet and all models of the FJ Printer easy to operate, main-
tain, and repair. It is the responsibility of the operator of the printer to monitor the performance of the
printer and maintain it in proper working condition by following the instructions in this manual and in
the product User Guide and to follow all safety precautions and warnings that are described in these pub-
lications. Ioline Corporation is not responsible for injuries that may occur as a result of unsafe use. Ioline
Corporation is not responsible for substandard operational performance as a result of failure to maintain
the printer as described in this manual and in the User Guide.
© 2003-2007 Ioline Corporation. All rights reserved. This manual may not be copied, photocopied, repro-
duced, translated, transmitted or converted to any electronic or machine-readable form in whole or in
part without prior written approval of Ioline Corporation.
Service and Support
If you require assistance with an Ioline product, your local Ioline dealer or authorized service center is ready
to help. Support information is also available 24/7 on the Ioline Web site—or you may contact Ioline directly:
Ioline Corporation
14140 NE 200th Street
Woodinville,Washington 98072 U.S.A.
Ioline Customer Service Department
Monday through Friday
7:00 A.M. - 5:00 P.M. U.S. Pacific Time
Voice: 1.425.398.8282
Fax: [phone]
[e-mail]
www.ioline.com
User Notice
Part Numbers: (Print) 109308 Rev. 0 • (File) 109307 Rev. 0

Service Manual
Ioline FJ Printer™
& StudioJet™

Images & Illustrations
Figure 1. Proper lifting procedure...................................................................................... xiii
Figure 2. The Ioline FJ (shown) and FJeX (not shown) Printers FrontView............. xvi
Figure 3. The Ioline FJ (shown) and FJeX (not shown) Rear View............................. xvii
Figure 4. The Ioline FJ Printer FrontView Close-up.................................................... xviii
Figure 5. The Ioline StudioJet FrontView......................................................................... xix
Figure 6. Power and communications ports on the Ioline StudioJet .............................. xx
Figure 7. The Ioline FJ Printer............................................................................................... 21
Figure 8. Paper direction....................................................................................................... 25
Figure 9. Carriage movement............................................................................................... 25
Figure 10. Workflow: output direct from CAD software (without FlexPlot)............. 27
Figure 11. Workflow using FlexPlot for file conversion and output.............................. 27
Figure 12. Control Center main menu................................................................................. 29
Figure 13. The Ioline FJ Printer power supply..................................................................... 33
Figure 14. Rear power panel assembly.................................................................................. 33
Figure 15. Pinchwheel assembly.............................................................................................. 34
Figure 16. Ink cartridges: HP 51645A................................................................................... 34
Figure 17. FJ Printer logic board............................................................................................ 34
Figure 18. Printer carriage assembly with cover off.......................................................... 35
Figure 19. Printer carriage assembly with cover on.......................................................... 35
Figure 21. Keypad LED error codes...................................................................................... 36
Figure 20. LED lights on the keypad...................................................................................... 36
Figure 22. The correct paper feeding path on the Ioline FJ Printer............................... 43
Figure 23. HP cartridges have an ink level indicator.............................................................................. 44
Figure 24. The ink cartridge is dirty, dry, or empty............................................................ 45
Figure 25. The ink cartridge requires cleaning.................................................................... 45
Figure 26. Damaged and dirty print cartridge.................................................................... 46
Figure 27. The Cartridge Calibration window in the Control Center.......................... 47
Figure 28. The Motion Adjust window.................................................................................... 48
Figure 29. The heads are drawing the lines too late on this plot................................... 48
Figure 30. The Frame Gap window....................................................................................... 50
Figure 31. Frame gaps on the plot......................................................................................... 50
Figure 32. Occasional frame gaps may indicate that the stand is not level.................. 50
Figure 33. The height-adjusting spacer.................................................................................. 51
Figure 34. The ink stall can crack if the cartridge door is not closed and locked...... 52
Figure 35. If the carriage makes noise, clean or replace the wheel................................ 52
Figure 36. A good transitor on the left; the one on the right is blown........................ 53
Figure 37. Testing the Y-Axis motor....................................................................................... 55

Figure 38. Mechanical, electrical and electronic diagnostics flow chart........................ 63
Figure 39. Left cover removal................................................................................................. 65
Figure 40. Right cover removal.............................................................................................. 65
Figure 41. Bottom cover removal steps...............................................................................66
Figure 42. Carriage replacement............................................................................................ 69
Figure 43. Carriage wheel replacement................................................................................ 70
Figure 44. Flex cable replacement......................................................................................... 73
Figure 45. Main logic board replacement............................................................................. 74
Figure 46. Power supply replacement................................................................................... 77
Figure 47. Bottom cover removal steps...............................................................................78
Figure 48. X-axis belt replacement........................................................................................ 80
Figure 49. Y-axis belt replacement......................................................................................... 81
Figure 50. X-motor replacement........................................................................................... 83
Figure 51. Y-transmission replacement.................................................................................................. 84
Figure 52. FJ Printer chassis BOM (exploded view A)............................................................... 96
Figure 53. FJ Printer chassis BOM (exploded view B)............................................................... 97
Figure 54. FJ Printer Parts List BOM.................................................................................................. 98
Figure 55. FJ-eX Printer chassis BOM (exploded view A).....................................................102
Figure 56. FJ-eX Printer chassis BOM (exploded view B).....................................................103
Figure 57. FJ-eX Printer Parts List BOM........................................................................................104
Figure 58. StudioJet chassis BOM (exploded)..............................................................................108
Figure 59. StudioJet Packing List.........................................................................................................109

Table of Contents
Safety & Cautions
Warranty
Policy
Ioline warranty policy ........................................................................................................... xiv
How to use this manual
Where to find information ................................................................................................ xv
What’s in this Service Manual ...................................................................................... xv
Visual Reference Guide
Chapter 1
Overview
Product overview .................................................................................................................. 21
Supported languages ............................................................................................................ 21
FJ Printer Specifications ...................................................................................................... 22
FJ-eX Specifications .............................................................................................................. 23
StudioJet Specifications ....................................................................................................... 24
How the printer works ....................................................................................................... 25
Paper movement .................................................................................................................. 25
Carriage movement ............................................................................................................. 25
Serial number identification ............................................................................................... 25
Glossary .................................................................................................................................. 26
Software setup options ....................................................................................................... 26
Power on .................................................................................................................................... 28
Installing FlexPlot and the Control Center .............................................................. 28
The Control Center ............................................................................................................. 29
Overview ................................................................................................................................ 29
Changing system settings .................................................................................................... 29
Control Center menu bar features .............................................................................. 30
File ......................................................................................................................................... 30
Communications .................................................................................................................. 30
Tools ........................................................................................................................................ 30
Help ......................................................................................................................................... 30

Control Center menu options ........................................................................................ 31
Software Version ................................................................................................................... 31
Cartridge Count ................................................................................................................... 31
Get Plotter Data .................................................................................................................. 31
Plotter Data (check box) .................................................................................................... 31
Line Width .............................................................................................................................. 31
Scale ......................................................................................................................................... 31
Frame Size .............................................................................................................................. 31
Quality Setting ...................................................................................................................... 32
Measurement Units .............................................................................................................. 32
Chapter 2
Nomenclature
Product components ........................................................................................................... 33
Chapter 3
Troubleshooting & Testing
General troubleshooting .................................................................................................... 37
Error messages ....................................................................................................................... 37
Control Center software errors ..................................................................................... 38
Keypad error codes .............................................................................................................. 40
Legend ..................................................................................................................................... 40
Power problems ..................................................................................................................... 41
Communications ................................................................................................................... 41
The Printer won’t respond to the computer ................................................................. 41
Serial communication ......................................................................................................... 41
Common problems .............................................................................................................. 42
Paper problems ...................................................................................................................... 47
Regular or intermittent paper tearing ............................................................................. 47
Media tracking ....................................................................................................................... 48
Print quality problems ........................................................................................................ 48
Line quality ............................................................................................................................. 48
Dirty or damaged cartridge ............................................................................................... 50
Cartridge calibration ........................................................................................................... 50
Calibration overview ........................................................................................................... 50
Cartridge alignment ............................................................................................................. 51
Motion adjustment ............................................................................................................... 52
Frame Gap Adjustment ....................................................................................................... 53
Unexplained frame gaps ...................................................................................................... 54
Frame Size Adjustment ........................................................................................................ 55
Ink cartridge stall problems ............................................................................................... 56
Noisy carriage movement ................................................................................................. 56
Mechanical, electrical, andelectronic diagnostics ................................................... 57
Electrical problems ............................................................................................................ 57
Troubleshooting sensors .................................................................................................. 57
General mechanical / electrical issues ............................................................................. 58
Simple electrical diagnostics test: ........................................................................... 59
Motor problems ................................................................................................................... 59

Testing the servo (Y-axis) motor ...................................................................................... 59
Testing the X-axis servo motor ........................................................................................ 60
Logic board assembly troubleshooting ............................................................................ 60
Logic board troubleshooting steps (Revision 2) ............................................................ 62
Service & support ................................................................................................................. 64
Getting help ............................................................................................................................. 64
Customer service .................................................................................................................. 65
Chapter 4
Repair Procedures
Maintenance procedures ................................................................................................... 67
Repair procedures ................................................................................................................. 67
Requesting service ................................................................................................................ 68
Cover removal procedures ............................................................................................... 69
Left cover removal ............................................................................................................... 69
Right cover removal ............................................................................................................. 69
Left bottom cover removal ................................................................................................ 70
Carriage Procedures ............................................................................................................ 72
Carriage replacement .......................................................................................................... 72
Carriage Wheel Replacement ............................................................................................ 74
Flex Cable Replacement ..................................................................................................... 76
Logic Board Procedures ..................................................................................................... 78
Logic board replacement .................................................................................................... 78
Note: Follow anti-static procedures ................................................................................ 79
Updating the firmware ........................................................................................................ 80
Electrical Procedures .......................................................................................................... 80
Power supply replacement ................................................................................................ 80
Keypad procedures ............................................................................................................... 82
Keypad replacement ............................................................................................................ 82
X-axis belt replacement ...................................................................................................... 84
Y-axis belt replacement ....................................................................................................... 86
X-motor replacement ......................................................................................................... 88
Y-transmission replacement ............................................................................................... 90
Chapter 5
Parts & Drawings
FJ Printer chassis (exploded view A) ............................................................................ 96
FJ Printer Chassis (exploded view B) .......................................................................... 95
FJ Printer Packing List ........................................................................................................ 97
FJ-eX chassis (exploded view A) ................................................................................ 102
FJ-eX chassis (exploded view B) ................................................................................ 103
FJ-eX Packing List .............................................................................................................. 104
StudioJet Chassis ................................................................................................................ 108
StudioJet Packing List BOM .......................................................................................... 109
Index

Safety &
Cautions
xiii
The Ioline FJ printer and StudioJet have many fast moving compo-
nents. Please read and follow these safety guidelines before begin-
ning operation of the printer:
Do not try to repair the machine without factory authoriza-
tion. Only qualified service personnel should attempt any
disassembly or access to internal components. If external
mechanical adjustments are necessary, turn off the printer and
disconnect it from all power sources (both the computer and
the wall outlet).
Be careful with hair, jewelry, or loose clothing near the printer.
They can become caught in the mechanical parts.
Never attempt to move the carriage by hand when the power is
on. Always use the Arrow keys to move the carriage.
To park the carriage
safely in the Service
Station and protect
the print cartridges,
press the Clean but-
ton.
Keep hands away
from the carriage
when the printer is in
operation. The car-
riage will automati-
cally move to touch
the left end plate then
back to the right end
(the Service Station
position) when the power is turned on.
Never insert hands or other objects into the Service Station
area on the right side of the printer. The carriage occasionally
enters this area without warning and could collide with an
obstruction, potentially causing and injury.
Be careful when moving or lifting the printer. Moving the print-
er requires at least 2 people. To avoid injury to your fingers, do
not lift the printer by the end plates. Hold the bottom surfaces
of the end covers to lift or move it. See Figure 1.
Keep fingers away from the drive shaft when the printer is in
operation. Serious injury could result.
Figure 1. Hold the bottom sur-
faces of the end covers to avoid injury to your
fingers.
To improve readability, the
StudioJet is mentioned in this
manual only when necessary to
clarify differences in service or
maintenance procedures vis à vis
the FJ Printer. Unless otherwise
noted, instructions pertaining to
the FJ Printer are identical for the
StudioJet.
Note



Warranty
Policy
Ioline warranty policy
Ioline Corporation provides a 12 month parts and labor warranty on
all new equipment and 90 days on repaired units, unless specifically
noted otherwise. Every unit is recorded by serial number when it
leaves the factory. The warranty period is based on the serial num-
ber of the unit and extends from the date of manufacture up to 12
months, plus an extra 3 months for shelf life. Making the total war-
ranty period 15 months from the date of manufacture.
For warranty service, the end user must work through their dealer.
Ioline Customer Service is available to assist Authorized Dealers
with customer and equipment support.
xiv

Four publications are available to assist you in setting up, operating
maintaining and servicing the FJ Printer:
FJ Printer Quick Start Guide (or StudioJet Quick Start Guide*)
FJ Printer & StudioJet User Guide
FJ Printer Service Manual
FlexPlot User Guide
Where to find information
The table below provides a quick directory of topics and resources:
How to use
this manual
Topic Manual
Assembly & setup Quick Start Guide
Paper loading Quick Start Guide
Removing markers User Guide
The Ioline Control Center (adjusting plot
parameters)
User Guide
Ioline FlexPlot software FlexPlot User Guide
Design software set-up guides FlexPlot User Guide
Maintenance User Guide
Basic troubleshooting User Guide
Advanced troubleshooting for qualified service
personnel
FlexPlot Service Manual
Specifications, part names, drawings FlexPlot Service Manual
What’s in this Service Manual
The FJ Printer & StudioJet Service Manual provides extensive
product specifications, testing and repair procedures.
Chapter 1 Introductory information and general specifications.
Chapter 2 Descriptive drawings listing part names for the FJ
Printer. This section is intended to supplement the
FJ Printer User’s Guide.
Chapter 3 Troubleshooting and testing guide.
Chapter 4 Details for repair and maintenance of the FJ Printer.
Chapter 5 Technical drawings and reference material.
* The FJ Printer and Studio-
Jet have separate Quick Start
Guides.When directed to consult
the Quick Start Guide, please
select the publication relevant to
your Ioline product.
Note


xv

xvi
A. Left End Cover
B. Pinchwheel lever
C. Right End Cover
D. Take-up Motor
E. Stand Leveling Foot
F. Feed Roll
G. Take-up Shaft
H. Feed Shaft
I. Dancer Bar
J. Stand
KEY
Figure 2.The Ioline FJ (shown) and FJeX (not shown) Printers FrontView.
E
A
C
F
H
J
D
G
I
B

xvii
Visual Reference Guide
Figure 3.The Ioline FJ (shown) and FJeX (not shown) RearView (head titled in maintenance position.)
K
L
MN
Q
O
P
K. Take-up Motor Cable
L. Take-up Motor Outlet
M. Power Switch
N. Serial & USB Ports
O. Paper Out Sensor
P. Platen Leveling Pad
Q. Cross-member*
* The FJ-eX has two cross-members
KEY
*

Figure 4.The Ioline FJ Printer Front View Close-up
R. Drive Shaft Marker
S. Pinchwheel Lever
T. Pinchwheel
U. Traverse or Carriage Rail
V. Carriage Assembly
W. Platen
X. Ink Cartridge Latch
Y. Ink Cartridge Stall
Z. Keypad
AA. Service Station
BB. Bottom Sensor
CC. Top Sensor
KEY
T
V
AA
Y
X
RU
CC
Z
BB
xviii
S
W

Visual Reference Guide
Figure 5.The Ioline StudioJet Front View.
ABC
H
G
M
L
N
K
D E
E
F
O
I
J
A. Left End Cover
B. Drive Shaft Marker
C. Pinchwheel Lever
D. Pinchwheel
E. Drive Shaft
F. Right End Cover
G. Keypad
H. Stand Leg
I. Inkjet Cartridge
J. Carriage
K. Stand Leveling Foot
L. Feed Shaft
M. Cross-member
N. Platen
O. Traverse
KEY
xix

Figure 6. Power and communications ports on the Ioline StudioJet are located on the back of the right cover.
P. Power Switch
Q. Serial (COM) Port
R. Power Cord
KEY
P
Q
R
xx